Embossed smart functional premium natural leather

ABSTRACT

A smart functional leather assembly includes a leather substrate, an electronic circuit layer including one or more conductive traces and optional electronic elements arranged on the leather substrate, optionally a pigmented coating arranged on the circuit layer, and an optional anti-soiling layer arranged on the pigmented layer. The entire smart functional leather assembly, including the circuit, are embossed to provide an embossed smart functional leather assembly with an embossed pattern.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. application Ser.No. 16/857,548, filed Apr. 24, 2020; which itself is a continuation ofU.S. application Ser. No. 16/185,633, filed Nov. 9, 2018; which itselfclaims priority to U.S. Provisional Patent Application Ser. No.62/667,178 filed May 4, 2018; and is a continuation-in-part applicationof U.S. application Ser. No. 15/635,803 filed Jun. 28, 2017; is acontinuation-in-part application of U.S. application Ser. No. 15/635,838filed Jun. 28, 2017; and is a continuation-in-part application of U.S.application Ser. No. 15/635,862 filed Jun. 28, 2017; all of which areexpressly incorporated herein by reference.

BACKGROUND

Interior vehicle components often include a surface layer of premiumnatural leather. The leather is wrapped around and secured to anunderlying structure. The leather is pliable, and thus conforms to thecontours of the underlying structure. In luxury vehicles, leather isgenerally applied as a surface layer over components that may come indirect contact with occupants of the vehicle, such as interior panels,seats, and door linings. The main function of the leather is foraesthetics and to provide a luxurious look to the interior of thevehicle. However, natural leather offers no functionality to the vehiclecomponents. Accordingly, there is a need for an improved surface layerfor vehicle components.

BRIEF DESCRIPTION

According to one aspect, a method of producing an embossed functionalleather assembly includes preparing a functional leather assembly, whichincludes providing a leather substrate comprising a first side and asecond side opposite from the first side; and applying a flexibleconductive trace over the first side of the leather substrate. Thefunctional leather assembly is embossed to provide an embossed textureat the first side of the functional leather substrate.

According to another aspect, a method of producing an embossedfunctional leather assembly includes providing a leather substratecomprising a first side and a second side opposite from the first side;arranging a pigmented coating on the first side of the leathersubstrate; applying a flexible conductive trace over the pigmentedcoating on the first side of the leather substrate; optionally applyinga topcoat over the flexible conductive trace; and embossing theresulting assembly to provide an embossed texture at the first side ofthe functional leather substrate.

According to another aspect, a method of producing an embossedfunctional leather assembly includes preparing a functional leatherassembly, which includes providing a leather substrate comprising afirst side and a second side opposite from the first side; applying aflexible conductive trace over the first side of the leather substrate;and arranging a pigmented coating on the first side of the leathersubstrate to thereby cover the trace. The functional leather assembly isembossed to provide an embossed texture at the first side of thefunctional leather substrate.

According to another aspect, method of producing a functional vehiclecomponent includes preparing a functional leather assembly by applyingan electronic circuit, including a flexible conductive trace, to a firstside of a leather substrate. The functional leather assembly is embossedto provide an embossed texture at the first side of the functionalleather substrate, and the functional leather assembly is arranged tocover a surface of a vehicle component such that the first side of theleather substrate faces away from the vehicle component.

According to another aspect, method of producing a functional vehiclecomponent includes preparing a functional leather assembly by applyingan electronic circuit, including a flexible conductive trace, to a firstside of a leather substrate; arranging a pigmented coating on the firstside of the leather substrate to thereby cover the circuit; and applyingan anti-soiling layer to the pigmented coating. The functional leatherassembly is embossed to provide an embossed texture at the first side ofthe functional leather substrate, and the functional leather assembly isarranged to cover a surface of a vehicle component such that the firstside of the leather substrate faces away from the vehicle component.

According to another aspect, a functional vehicle component comprises afunctional leather assembly. The functional leather assembly includes aleather substrate comprising a first side and a second side oppositefrom the first side, and a flexible electrically conductive tracearranged on the first side of the leather substrate. The functionalleather assembly is embossed with an embossed texture at the first sideof the leather substrate.

According to another aspect, a functional vehicle component comprises afunctional leather assembly. The functional leather assembly includes aleather substrate comprising a first side and a second side oppositefrom the first side, a flexible electrically conductive trace arrangedon the first side of the leather substrate, and a pigmented coating onthe first side of the leather substrate and covering the trace. Thefunctional leather assembly is embossed with an embossed texture at thefirst side of the leather substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective exploded view of a smart functionalvehicle component includes a smart functional leather assembly accordingto the present subject matter.

FIG. 2 is a schematic view a smart functional leather assembly beingembossed according to the present subject matter.

FIG. 3 is a method of preparing an embossed smart functional leatherassembly according to the present subject matter.

FIG. 4 is a method of preparing a smart functional leather assemblyaccording to the present subject matter according to the present subjectmatter.

FIG. 5 is a schematic perspective view of a vehicle component includingan embossed smart functional leather assembly according to the presentsubject matter.

DETAILED DESCRIPTION

Smart functional vehicle components can be used to make an occupant'sexperience in the vehicle more comfortable and enjoyable as compared tonon-functional vehicle components.

The present subject matter provides a smart functional leather assemblythat is flexible, and therefore can be wrapped around or over variousvehicle components to make the vehicle components smart and functional.The smart functional leather assembly can be arranged on an interior orexterior of a vehicle. The outermost surface of the smart functionalleather assembly presents a clean finish to a vehicle component, andtherefore has an uncluttered appearance despite having a smartfunctional capacity.

The present subject matter includes a smart functional leather assembly,and a method of making a leather substrate to be smart and functional,as opposed to being used for only aesthetic purposes, without clutteringthe appearance of the leather substrate. For this purpose, the smartfunctional leather assembly may include electronic elements includingfor example, traces, switches (e.g. actuator buttons), sensors, or otherfunctional or smart elements on a first side of the leather substrate.When used in an interior of a vehicle, the functional leather assemblycan provide a dynamic interior experience for occupants of a vehicle,yet provide a smart functional vehicle component that has an unclutteredappearance.

Referring now to the figures, where the depictions are for purposes ofillustrating one or more embodiments only and not for purposes oflimiting the same, the present subject matter includes a smartfunctional leather assembly 2 (also referred to herein as “functionalleather assembly” or “leather assembly”). As depicted, the functionalleather assembly 2 includes a leather substrate 4, an electronic circuitlayer 14, a pigmented coating 26, and an optional anti-soiling layer 28.

The leather substrate 4 may be in the form of a leather sheet, includinga first side 6 and a second side 8 opposite from the first side 6. Thefirst side 6 of the leather substrate 4 may face the same direction asan A-surface 10 of the functional leather assembly 2 (see FIG. 5 ). Asused herein, “A-surface” refers to the outermost surface of the leatherassembly 2 that is most visible to (i.e. most facing) vehicle occupantsafter the functional leather assembly 2 including the leather substrate4 is arranged in a vehicle; while a B-surface, a C-surface, a D-surface,etc. are other surfaces of the leather substrate 4 that areprogressively less visible than the A-surface 10. When arranged on avehicle component 40 to produce a smart functional vehicle component 12(FIG. 5 ), the A-surface 10 of the functional leather assembly 2 isfacing the vehicle occupants and unless covered by another layer orfeature, may be visible to the occupants of the vehicle. The A-surface14 may be what is referred to in the leather industry as the grain side,the skin side, the top side, or the hair side of the leather sheet 10.The grain side, the skin side, the top side, or the hair side is theside of the leather sheet 10 opposite from what is referred to in theleather industry as the flesh side or back side of the leather sheet 10.The flesh side is the side of the leather sheet 10 that is connected tothe meat of the animal from which the leather sheet 10 is taken.

The leather substrate 4 may be processed from natural animal hide, ormay include composite leather (e.g. bonded leather) or synthetic leatherproducts. When natural animal hide is used as the leather substrate, theanimal hide may be subject to a leather preparation processes includingone or more of tanning, soaking, sammying, shaving, fleshing/splitting,drying, staking, milling, and drying. Then, after application of a basecoat, the hide may be cut into a desired shape for a particularapplication, for example to cover a seat, interior panel, steeringwheel, or other vehicle component 40 in a vehicle to form the smartfunctional vehicle component 12. The hide may be cut or formed to aparticular size or shape to correspond to the shape and size of thevehicle component 40 on which it will be arranged. The natural animalhide may be replaced or supplemented with bonded leather, syntheticleather, other leather composite material, or other material or layersas desired. In accordance with the present subject matter, the leathersubstrate 4 may have a shape and size that is configured to wrap aroundor over a surface 42 of an interior panel, a door, a seat (FIG. 5 ), asteering wheel, a dashboard, a center console, or a gear shifter forexample.

After the leather substrate 4 is prepared as desired, the electroniccircuit layer 14, pigmented coating 26, and optional anti-soiling layer28 may be applied to the leather substrate 4 to form a leather assembly2. In one embodiment, the electronic circuit layer 14, pigmented coating26, and optional anti-soiling layer 28 allow some characteristics (e.g.surface texture or grain, and softness) of the leather substrate 4 to beat least partially perceived by occupants of the vehicle, such as bytouch or sight.

The electronic circuit layer 14 (also referred to herein as “circuitlayer” or “circuit”) is flexible, and is arranged on the first side 6 ofthe leather substrate 4, optionally in direct contact with the firstside 6 of the leather substrate 4 or having one or more interveninglayers arranged therebetween. The circuit 14 includes one or moreflexible electrically conductive traces 16 (also referred to herein as“flexible conductive traces,” “conductive traces,” or “traces”). As usedherein, “electrically conductive” or “conductive” refers to a materialor structure that can transmit an electric current or signal. By“flexible”, it is meant a layer, circuit, trace or other element ormaterial that is not rigid, brittle, or stiff, and instead bends,stretches, changes shape, or otherwise yields to external forces, yetdoes not break or lose functionality when subject to such externalforces. When referring to a “flexible electronic circuit” or “flexibleconductive trace”, it is meant that the electronic circuit 14 and trace16 retrain their electrical conductivity even when bent, stretched,twisted or otherwise deformed to a strain of 10% to at least 20%. In oneembodiment, the circuit 14 and traces 16 do not break when so deformed.

The circuit 14 optionally includes one or more electronic elements (e.g.light sources 18, switches 20, sensors 22, wireless transmitters 24,resistors, capacitors, wires, diodes, transistors, inductors, powersources, transformers, fuses, antennas, or the like, each of which maybe flexible) that are in electrical communication with the traces 16. Inan alternative embodiment, these electronic elements of the circuit 14may be arranged elsewhere other than as part of the circuit 14, butstill in electrical communication with the conductive traces 16. Thecircuit 14 is arranged on the first side 6 of the leather substrate 4 inorder to provide functionality to the leather substrate 4.

Although the circuit 14 is depicted in FIGS. 1 and 2 as a continuouslayer, this is done for convenience in order to show the arrangement ofthe various components of the smart functional leather assembly 2, andit should be understood that the circuit 14 may not be a continuouslayer, but instead may include the traces 16 that are applied directlyto the leather substrate 4 and therefore include one or more gapsbetween the traces 16 and the one or more optional electronic componentsof the circuit 14. However, the circuit 14 may be a continuous layer asdepicted, such as for example, the circuit 14 may be formed on a surfaceof a film, and the film carrying the circuit 14 may be applied directlyto the leather substrate 4.

The circuit layer 14 may comprise one or more electrically isolatedcircuits. In one embodiment, the circuit layer 14 includes only oneelectronic circuit. In another embodiment, the circuit layer 14 includesmore than one electronic circuit, for example, two, three or moreelectronic circuits. When more than one circuit is included in thecircuit layer 14, each individual circuit may each be configured toperform a different function than the other circuits, which may meanthat each circuit is electrically isolated/separated from the othercircuits, or the circuits can be independently operated, or each circuitcan function separately from the other circuits, or the circuits areelectrically connected to different types of electronic elements of thecircuit layer 14.

The circuit 14 includes at least one flexible conductive trace 16.Further, as will be understood, the figures only schematically depictthe traces 16, and are not meant to restrict the traces 16 to be in anyparticular arrangement. In one non-limiting embodiment, the circuit 14contacts the first side 6 of the leather substrate 4. In anotherembodiment, the circuit 14 is arranged on a polymer film, which is thenarranged on the first side 6 of the leather substrate 4.

The conductive traces 16 and electronic components may each be formedusing an electrically conductive ink that includes a binder (e.g.polymer material such as polyimide) and conductive particles, includingfor example, copper, silver, carbon, silver chloride, or otherelectrically conductive particles. Optionally, the one or more optionalelectronic elements of the circuit 14 can comprise prefabricated unitsthat are electrically connected to the traces 16 by using a conductiveadhesive for example.

The one or more conductive traces 16 and optional electronic elements ofthe circuit 14 may each be formed by applying, e.g. printing, aconductive ink directly on the first side 6 of the leather substrate 4,followed by curing, drying, hardening, etc. of the conductive ink tothereby form the conductive traces 16, and electronic elements of thecircuit 14. In other words, the conductive traces 16 and electronicelements of the circuit 14 may be defined by, or include a printed andcured conductive ink. Conductive inks that are suitable to create theone or more traces and electronic elements of the circuit 14 are notparticularly limited, and may include conductive metal (e.g. silver) orother particles, and can include for example, PE671, PE773, PE873, andPE971 Stretchable Conductors, PE410 Ink-Jet Silver Conductor, 5021,5025, 5028, and 5064HY Ag Conductors, ME601 and ME602 Stretchable SilverConductors, PE827 and PE828 Ultra-Low Temperature Cure Silver CompositeConductors, Kapton™ KA801 Polyimide Silver Conductor, available from E.I. du Pont de Nemours and Company; and CI-1036, CI-4040, CI-2051, andCI-1062 Stretchable Conductive Ink available from Engineered MaterialsSystems, Inc. (EMS).

These conductive inks can be applied directly on the first side 6 of theleather substrate 4, or on a film that is to be arranged on the firstside 6 of the leather substrate 4. The conductive ink can be applied byany method including pad-printing, flexography, rotogravure, spraying,dipping, syringe dispensing, stenciling, screen printing, aerosol jetprinting, or inkjet printing for example in order to create anelectronic circuit. The flexible electrically conductive traces 16 canbe formed using other materials or processes including etching, in-moldforming of the electronic circuits, selective photocuring, and circuitscribe, for example. In one illustrative embodiment, the one or moreconductive traces 16 are formed by screen printing a conductive ink onthe first side 6 of the leather substrate 4.

In one non-limiting example, one or more light sources 18 are includedas an electronic element in the functional leather assembly 2. The lightsources 18 may comprise for example, a light emitting diode (LED), anelectroluminescent light source, or other light source. The lightsources 18 emit light when activated, and are electrically connected tothe circuit 14. The light sources 18 may simply provide illumination byemitting light, which may be used to provide illumination to theinterior or exterior of the vehicle, and the light sources 18 may emitlight in one or more colors and/or intensities. The light sources 18 maybe paired to certain functions of the vehicle or vehicle components,such that the light sources 18 operate to emit light at differentintensities and/or colors depending on certain circumstances such asduring normal operation of the vehicle, during operation of a vehicleentertainment system, during dangerous operation of the vehicle, orother circumstances or situations as desired.

The light source 18 may be configured, such as by arrangement oroperation, to emit light that provides visual indicators that conveyinformation to a vehicle occupant. In other words, the light source 18may be arranged, or may emit light in such a way that the light emittedby the light source 18 provides more than mere illumination, and insteadadditionally conveys information to a vehicle occupant. The visualindicators provided by the light source 18 may correspond to signals ordata derived from the electronic systems of a vehicle or the HMI 34. Thevisual indicators provided by the light source 18 are not particularlylimited by the present disclosure, and may provide information such aswarnings, notices (e.g. the time), alerts, instructions, informationrelating to a current condition or situation relating to the vehicle orvehicle components, an occupant of the vehicle, or an environment of thevehicle including an immediate surrounding environment of the vehicle,and combinations thereof.

The light emitted by the light source 18 may indicate a location of thecircuit 14 or the location of the various electronic elements of thecircuit 14. The light source 18 may also be activated to emit light whena certain associated object is within a predetermined distance from thefunctional leather assembly 2. For example, the light source 18 may beactivated to emit light when a portable electronic device or vehicleoccupant is within a predetermined distance from the functional leatherassembly 2.

The light source 18 is not limited in any way and can includeluminescent light sources (e.g. electroluminescent, photoluminescent,mechanoluminescent light sources), and incandescent light sources.Illustrative examples of the light source 18 include a light emittingdiode (LED), an organic light emitting diode (OLED), or aphotoluminescent or electroluminescent light source configured in a filmor sheet. In a non-limiting example, the light source 18 comprises LED'shaving a light emitting area with a size of 100 μm×100 μm (i.e. 100 μmdiameter) or less, herein referred to micro LED's. A micro LED comprisesof an array of one or more individual light emitters, where an array mayhave a diameter of about 2 μm-20 mm and the individual light emittershave typical diameters of about 2-20 μm. In one aspect, the one or moremicro LED's are arranged as part of the circuit 14.

One or more sensors 22 may be included as part of the circuit 14. Thesensors 22 are not particularly limited, and can include a sensor havingany configuration including those that can sense pressure, temperature,proximity, location, speed, velocity, acceleration, tilt, motion,humidity, light, biometrics of a vehicle occupant, etc. In oneembodiment, the circuit 14 includes one or more pressure sensors.

As described herein, a switch 20 may be included in the electroniccircuit 14. The switch 20 may be operable to make or break a conductivepath in the circuit 14 in order to activate a particular function of thecircuit 14, the electronic elements of the circuit 14, or a vehiclesystem or component. The switch 20 may be a parallel plate capacitiveswitch for example, or other type of switch as desired such as amembrane switch. The switch may define a button that can be actuate byan occupant of the vehicle making contact with the switch.

The leather assembly 2 also includes a pigmented coating 26 arranged onthe circuit 14 to at least partially conceal the circuit 14, or on thefirst side 6 of the leather substrate 4 between the leather substrate 4and the circuit 14. The pigmented coating 26 may be arranged directly incontact with the circuit 14 or may be arranged with one or moreintervening layers therebetween. In an embodiment, the pigmented coating26 is not included, or the pigmented coating 26 may be clear (i.e.optically transparent) and/or the circuit 14 and electronic elementsthereof may be positioned on top of the pigmented coating 26. Thepigmented coating 26 is not particularly limited by the present subjectmatter, and may include one or more translucent layers, films, orcoatings arranged on the flexible circuit 14. By “translucent” it ismeant material(s) or a layer(s) that allows light to pass therethrough,but causes sufficient diffusion to prevent perception of distinct imagesthrough the material or layer. In accordance with the present subjectmatter, the pigmented coating 26 may produce sufficient diffusion oflight such that visibility through the pigmented coating 26 of theflexible electronic circuit 14 and all the electronic elements of thecircuit 14, except for light emitted by the light source 18, isinhibited or prevented by the pigmented coating 26. In one embodiment,the flexible electronic circuit 14 and all the electronic elements ofthe circuit 14 are camouflaged by the pigmented coating 26. In anon-limiting example, the flexible electronic circuit 14 and all theelectronic elements of the circuit 14 are not visible through thecoating 26

Visibility of the light source 18 through the pigmented coating 26 isoptionally inhibited by the pigmented coating 26 so that the lightsource 18 is camouflaged by the pigmented coating 26. However, thepigmented coating 26 may be sufficiently translucent (rather than beingcompletely opaque) such that when the light source 18 is activated toemit light, the light emitted by the light source 18 is visible throughthe pigmented coating 26. Accordingly, the pigmented coating 26 at leastin some measure may conceal the flexible circuit 14 (including the lightsource 18) from view, yet allows light emitted from the light source 18to be transmitted therethrough so that the emitted light is visiblethrough the pigmented coating 26 and can be seen. Light emitted from thelight source 18 that is transmitted through the pigmented coating 26 maybe seen for example, by a vehicle occupant, and can be used for vehicleillumination or as visual indicators to convey information to a vehicleoccupant.

The pigmented coating 26 may include a polymer, textiles, compositematerials, enamels, paper, glass, metal, ceramic, other material, andcombinations thereof. In one non-limiting example, the pigmented coating26 comprises one or more layers, each including for example, a mixtureof polymer and pigment particles. The polymer may be an acrylic urethaneresin for example. The pigmented coating 26 may be formed by applyingone or more coatings of the polymer/pigment mixture as a liquid over theflexible circuit 14 and curing the polymer to produce the pigmentedcoating 26 as a solid layer covering the circuit 14. The pigmentedcoating 26 may have a pigment loading and thickness sufficient toinhibit or prevent the circuit 14 and the electronic elements of thecircuit 14, including the light source 18, from being visible throughthe pigmented coating 26. However, the pigmented coating 26 issufficiently translucent, as opposed to being completely opaque, suchthat light emitted by the light source 18 can be seen through thepigmented coating 26. In one non-limiting embodiment, the pigmentedcoating 26 has a thickness from 5-50 μm, 15-40 μm, or 20-30 μm. Otherthicknesses can be used.

In one embodiment for example, the pigmented coating 26 includes amulti-layer structure including a 20-45 microns thick base color layerthat is applied wet on the leather substrate 4 and dried at about 100°C. for one minute; a 15-20 micron thick color coat is then applied wetand dried at 100° C. for one minute; and then three layers of topcoateach at 5-20 microns thick (for a total of 15-60 microns thickness) areapplied wet and then dried at 100° C. for one minute. The base colorlayer, the color coat, and the topcoat layers may each be applied byspraying and each may comprise a polyurethane acrylic dispersion withpigment. The base color layer and color coat are included to provideabrasion resistance and color consistency. The topcoat is provided forhaptics and color performance. The leather substrate may also be coatedinitially with a base coat of polyurethane and acrylic dispersion,applied by a roller, and included to provide adhesion to the leathersubstrate 4.

The leather assembly 2 optionally includes an anti-soiling layer 28arranged on the pigmented coating 26. The anti-soiling layer 28 includesan anti-soiling component for inhibiting the aggregation of soil, dirt,stains or other debris on the leather assembly 2. In one non-limitingembodiment, the anti-soiling layer 28 includes a polymer carrier that isapplied at 1-10 microns thick and then dried at 100° C. for one minuteto form a coating on the leather assembly 2. Other carriers,thicknesses, and drying times and temperatures may be used. In analternative embodiment, the functional leather assembly 2 may notinclude a separate and distinct anti-soiling layer 28, and can insteadinclude an anti-soiling component as part of the pigmented coating 26.

The anti-soiling layer 28, or an anti-soiling component included in thepigmented coating 26, may present an exposed outermost surface (i.e.A-surface 10) of the functional leather assembly 2, and these areoptionally included to resist any type of dirt accumulation on theleather assembly 2 while possibly retaining at least some physical andaesthetical properties of the underlying layers of the functionalleather assembly 2. The anti-soiling layer 28 is not particularlylimited by the present subject matter, and may be included as a distinctlayer as depicted in FIGS. 1 and 2 . Alternatively, an anti-soilingcomponent may be included as part of the pigmented coating 26. In anon-limiting embodiment as depicted in FIG. 1 , when included as adistinct layer in the functional leather assembly 2, the anti-soilinglayer 28 may be essentially transparent (and may be opticallytransparent) such that the anti-soiling layer 28 does not significantlyinterfere with the transmission of light emitted by the light source 18or affect the aesthetics of the pigmented coating 26. In anotherembodiment, the anti-soiling layer 28 may be pigmented such that itassists the pigmented coating 26 in concealing the circuit 14 from view.In one non-limiting embodiment, the anti-soiling layer 28 has athickness from 0.1-10 μm, 1-8 μm, or 4-6 μm.

The anti-soiling component included in the anti-soiling layer 28 or inthe pigmented coating 26, is not particularly limited and may compriseacrylic urethane resin, polyurethane resin, polyisocyanate,carbodiimide, fluorine-containing materials such as tetrafluoroethylene(TFE)-copolymers, silicone, etc.

The functional leather assembly 2 can include various other layers orcomponents as desired. In one embodiment and although not shown in thefigures, the functional leather assembly 2 includes a dielectric layerover or between one or more conductive traces 16 or conductive traces 16of the circuit 14. The dielectric material may generally include anon-conductive resin cured to form a dielectric layer. In oneembodiment, a dielectric layer is arranged between the circuit 14 andthe pigmented coating 26 in order to avoid moisture exposure duringformation of the pigmented coating 26, or to make the circuit 14 moredurable and resistant to abrasion and therefore maintain electricalconductivity after repeated use. A dielectric layer or coating may alsobe used as an insulator, for example, to provide electrical insulationbetween a first trace or circuit and an overlying second trace orcircuit.

The dielectric layer may cover only the trace or circuit, or may alsogenerally cover other portions of the circuit 14 or leather substrate 4.That is, the dielectric layer may be generally applied over the firstcircuit as one continuous layer, where the conductive traces of thefirst circuit and spaces therebetween are covered by the dielectriclayer, or may be applied as a discontinuous layer that covers only theconductive traces of the first circuit, but not the spaces therebetween.In one non-limiting example, the dielectric layer is applied only at alocation where a second trace or circuit overlaps the first trace orcircuit. In this regard, the circuit 14 may include a plurality ofseparate and distinct traces 16 that may be arranged in different planesor sub-layers of the circuit layer 14, where various conductive traces16 may overlap each other. For example, with reference to FIGS. 1 and 5, although the traces 16 are depicted as not overlapping (and appear tobe in the same plane or sub-layer), the traces 16 may be in differentplanes within the circuit layer 14 and be configured to overlap eachother. As such, the circuit 14 may include a first trace printed on theleather substrate 4, followed by a dielectric layer applied over thefirst trace, and then a second trace printed on the leather substrate 4and at least partially overlapping the first trace, yet because of theintermediary dielectric layer, the first and second trace areelectrically isolated form one another. As such, the present subjectmatter is not limited to any particular shape or orientation of thetraces 16 and electronic elements of the circuit 14 as depicted in thevarious figures, and instead can have other arrangements andorientations. In another example, a conductive ink is first printeddirectly on the leather substrate 4 in order to form a wirelesstransmitter 24, a dielectric layer is then arranged over the wirelesstransmitter 24, then a conductive ink is printed over the dielectriclayer (or overlaps a portion of it) in order to form a separateconductive trace for a different electronic element (e.g., for a lightsource 18), and then optionally another dielectric layer is printed overthe light source trace to provide abrasion resistance for the underlyinglayers. In this example, the dielectric layer between the wirelesstransmitter 24 and the light source trace electrically isolate thewireless transmitter 24 from the light source trace.

The entire leather assembly 2 is embossed as depicted in FIG. 2 , toprovide an embossed texture at the A-surface 10 of the leather assembly2. The functionality of the circuit 14 is not destroyed by embossing. Inother words, electrical conductivity of the conductive traces 16 is notbroken by embossing the functional leather assembly 2 and the optionalelectronic elements of the circuit 14 are still functional afterembossing. The circuit 14 is therefore able to perform electronicoperations even after embossing the leather assembly 2.

Embossment of the leather assembly 2 can comprise roll-to-roll heatedembossment accomplished by processing the leather assembly 2 throughheated embossing rollers 30, 30 to impart the embossed texture at thefirst side 6 of the leather substrate 4. Roll-to-roll heated embossmentcan comprise embossment at conditions of 80-100° C., 20-30 Bar, anddwell speed of 2.5-4.5 to apply natural leather grain embossment patternto the A-surface 10 of the functional leather assembly 2. Embossment ofthe leather assembly 2 can comprise other methods, includingroll-to-plate, roll-to-die, stamping, clamping, punching, pressing, andthe use of various embossing rollers, embossing dies, embossing stamps,or other embossing tools. The embossed texture is not particularlylimited, and may include leather grain, dimples or other textures,patterns, indicia, or a combination thereof. The leather grain texturecan include reproductions of various animal grains, including cow,snake, crocodile, other animals, and variations and combinationsthereof. Through applying different types of embossment, the smartfunctional leather assembly 2 can have different types of aestheticappearances and feel, while maintaining functionality imparted by thecircuit 14.

The embossed texture is applied directly to the A-surface 10 of theleather assembly 2 and over the circuit 14, for example as depicted inFIG. 2 . The embossing parameters (e.g. the pressure applied to theleather assembly 2 by the embossing rollers 30, 30, the dwell time ofthe leather assembly 2 between the embossing rollers 30, 30, and thetemperature of the embossing rollers 30, 30) and parameters of thevarious components of the leather assembly 2 (including for example, thethicknesses and compositions of the leather substrate 4, the circuit 14,the pigmented coating 26, and the anti-soiling layer 28) a can betailored to avoid the functionality of the circuit 14 from beingeliminated by the embossment. In one embodiment, the functionality ofthe circuit 14 is not eliminated by the embossment process, such thatthe electrical conductivity of the conductive traces 16 is not brokenand the functionality of the other electronic components is noteliminated by embossing of the functional leather assembly 2. Thefunctionality of the circuit 14, including the conductive traces 16 andelectronic components, can be assessed after embossing the functionalleather assembly 2.

The functional leather assembly 2 can be arranged to a vehicle component40 to form a smart functional vehicle component 12 (also referred toherein as “functional vehicle component”). The embossed functionalleather assembly 2 may be included on any vehicle component 40 asdesired, for example on any surface 42 of an interior or exteriorvehicle component 40, such as a vehicle seat (FIG. 5 ), dashboard, orcenter console for example.

The functional vehicle component 12 is not particularly limited by thepresent subject matter, and may comprise any interior functional vehiclecomponent such as an interior panel, a door, a seat (FIG. 5 ), asteering wheel, a dashboard, a center console, a gear shifter or anyother interior component that can be wrapped, covered, or coated withthe embossed functional leather assembly 2. Optionally, the functionalvehicle component 12 can include an exterior functional vehiclecomponent. The embossed functional leather assembly 2 can be arranged incontact with a surface 42 of the vehicle component 40 to make thevehicle component 40 to be functional. The surface 42 of the vehiclecomponent 40 to be covered by the embossed functional leather assembly 2may be smooth or textured, flat or contoured, and the vehicle component40 may be rigid or pliant (such as a cushion on a seat). In any event,the embossed functional leather assembly 2 is arranged with respect tothe vehicle component 40 in order to make the functional vehiclecomponent 12, which is smart and functional.

The embossed functional leather assembly 2 is arranged on the vehiclecomponent 40 in order to enhance, not only the functionality, but alsothe aesthetics of the vehicle component 40. The leather substrate 4 isnaturally flexible, pliable, and stretchable, and therefore the embossedfunctional leather assembly 2 is also flexible and can therefore bewrapped around or over, or applied to the vehicle component 40 andconformed to the contours of the surface 42 of the vehicle component 40.The embossed functional leather assembly 2 may be arranged on thevehicle component 40 by stretching and wrapping the embossed leatherassembly 2 around the vehicle component 40. The embossed functionalleather assembly 2 may be fixed, such as by adhesive or fasteners, tothe vehicle component 40. Because the circuit 14, including traces 16,are also flexible, the circuit 14 and traces 16 can at least partiallyconform to the contours of the surface 42 of the vehicle component 40without eliminating their functionality. The embossed functional leatherassembly 2 may be in direct contact with the surface 42 of the vehiclecomponent 40, or may have one or more optional layers arrangedtherebetween. Optionally, the embossed functional leather assembly 2 maysimply cover or be arranged over the surface 42 of the vehicle component40.

Once installed in the vehicle, operation of the embossed functionalleather assembly 2, the circuit 14, the electrically conductive traces16, and the associated electronic elements of the circuit 14, maycorrespond to signals or data derived from one or more electronicsystems of a vehicle or may be intermittently or continuously activatedduring operation of the vehicle. The data or signals may be accessedfrom, sensed by, generated by, or otherwise acquired from or produced byone or more vehicle electronic systems. Further, the embossed functionalleather assembly 2, the circuit 14, the electrically conductive traces16, and the associated electronic elements of the circuit 14 may providesignals or data to the one or more electronic systems of the vehicle.

The vehicle electronic systems from which this data or these signals maybe derived, or to which this data or these signals may be communicated,are not particularly limited and may include one or more vehicleelectronic control units (ECU's) associated with a vehicle engine,transmission, body, chassis, passive and active safety features, vehicleperformance, driver assistance, interior and exterior environment,vehicle diagnostics, vehicle control, audio/visual entertainment,navigation, electrical systems, telematics, and combinations thereof.The vehicle electronic systems can include a door control unit, enginecontrol unit, electric power steering control unit, human-machineinterface (HMI), powertrain control module, transmission control unit;seat control unit, speed control unit, telematics control unit,transmission control unit, brake control module (ABS or ESC), batterymanagement system, central control module, central timing module,general electronic module, body control module, suspension controlmodule, or combinations thereof.

In another embodiment, the embossed functional leather assembly 2includes a microcontroller 38 electrically connected to the circuit 14,e.g. at an edge of the leather substrate 4. The microcontroller 38 maybe electrically connected to the circuit 14 after embossment of thefunctional leather assembly 2. The microcontroller 38 may be used tomake an electrical connection to the circuit 14, and thus may providecommunication to and from the one or more conductive traces 16 andelectronic elements of the circuit 14, or to control functions of theone or more conductive traces 16 and electronic elements of the circuit14. The microcontroller 38 may be mounted at the edge of the leathersubstrate 4 and embossed functional leather assembly 2 before or afterthe embossed functional leather assembly 2 is fixed over the first side6 of the vehicle component 40. Various vehicle electronic systems, suchas an electronic control unit 32 (ECU), human machine interface 34(HMI), or vehicle power source 36, may be electrically connected to thefunctional leather assembly 2 through the microcontroller 38 in order tocommunicate with the embossed functional leather assembly 2. The circuit14 may also be electrically connected to the vehicle ECU 32, the vehiclepower source 36, the vehicle HMI 34, or other vehicle systems by directconnection with a conductive lead.

The ECU 32 may control operation of the embossed functional leatherassembly 2, the electrically conductive traces 16, and the associatedelectronic elements of the circuit 14. The ECU 32 may be electricallyconnected to the vehicle power source 36 for powering the ECU 32 and/orthe circuit 14.

The HMI 34 may be used to control functioning of the embossed functionalleather assembly 2 and the circuit 14, including the electricallyconductive traces 16 and the associated electronic elements of thecircuit 14. Such arrangement could allow a user to provide input throughthe HMI 34 to selectively activate the electronic elements of thecircuit 14 to perform a particular function. Such user input may beactive (user initiated) or passive (sensed input from a user), and caninclude audible or tactile input. The system may be configured to allowa user to audibly select an operation of the functional leather assembly2, the circuit 14, the electrically conductive traces 16, and theassociated electronic elements of the circuit 14. Alternatively, anoperation of the embossed functional leather assembly 2 may becontrolled by an integral actuator button (e.g. switch 20) included inthe circuit 14.

The circuit 14 and the electronic elements of the circuit 14 may beelectrically connected to a power source 36 of the vehicle for providingelectrical power to the circuit 14 for activating the electronicelements of the circuit 14. The vehicle power source 36 may comprise avehicle battery, engine, or alternator, for example. The power source 36may be connected to the embossed functional leather assembly 2 throughthe microcontroller 38. In one embodiment, a smart functional vehiclesystem includes the embossed smart functional leather assembly 2, alongwith one or more of the microcontroller 38, ECU 32, HMI 34, and vehiclepower source 36.

The embossed functional leather assembly 2, including the one or moreconductive traces 16 along with the various electronic elements of thecircuit 14, may be selectively operable based on a current condition orsituation relating to the vehicle or vehicle components, an occupant ofthe vehicle, or an environment of the vehicle including an immediate ora distant surrounding environment of the vehicle, and combinationsthereof. A non-limiting example of the conditions of the vehicle thatmay be used as a basis for such selective operation include historical,current, or projected vehicle performance characteristics or diagnosticinformation, or the like. Conditions of the vehicle occupants that maybe used as a basis for such selective operation can include a physicalcondition of a driver, such as the driver being drowsy or inattentivewhile driving, or the proximity of an object (such as an occupant or anoccupants hand) or a global position relative to the vehicle or to theembossed functional leather assembly 2. Conditions of the surroundingenvironment that may be used as a basis for such selective operation caninclude proximity of an object (such as another vehicle) to the vehicle,the current time, newsfeeds, amber alerts, nearby points of interest, orthe like.

With reference to FIG. 5 , an illustrative example of the embossed smartfunctional leather assembly 2 is included as part of a smart functionalvehicle component 12 (i.e. vehicle seat). The smart functional vehiclecomponent 12 includes the embossed functional leather assembly 2arranged on the seat as depicted. It will be appreciated that althoughvisibility of the circuit 14 may be inhibited or prevented by thepigmented coating 26, the circuit 14 in FIG. 5 is schematically depictedin order to indicate its arrangement on the smart functional vehiclecomponent 12. As in other embodiments, the embossed functional leatherassembly 2 of the vehicle seat may include one or more electronicelements in the circuit 14. As depicted, the circuit 14 of the embossedfunctional leather assembly 2 of the seat includes traces 16, lightsources 18, a switch 20, a sensor 22, and a wireless transmitter 24.More or less, and different electronic elements may be included in thecircuit 14 of the seat, and the functional leather assembly 2 andcircuit 14 may be arranged at different locations on the seat, includingon the seat cushion, the headrest, or an armrest (not shown).

The present subject matter also includes a method 44 of producing anembossed functional leather assembly 2. As depicted in FIG. 3 , themethod 44 includes a step 46 of preparing a smart functional leatherassembly 2, and then a step 48 of embossing the smart functional leatherassembly 2. A step 46 of method 44 of FIG. 3 may include, in whole or inpart, a method 50 (FIG. 4 ) of producing a functional leather assembly.The method 50 of FIG. 4 includes a step 52 of providing a leathersubstrate 4, applying a circuit 14 to the leather substrate 4 at step54, optionally connecting an electronic element to the circuit 14 atstep 56, applying a pigmented coating 26 on the circuit 14 at step 58,and applying an anti-soiling layer 28 on the pigmented coating 26 atstep 60.

The leather substrate 4 may be provided in step 52 of method 50, as ananimal hide preliminarily prepared before application of the circuit 14by passing the animal hide through various processes such as soaking,sammying, shaving, fleshing/splitting, drying, staking, and milling.Then, after application of a base coat, the hide may be set aside torest. The hide may then be cut to a predetermined shape to produce aleather substrate 4 that can be arranged on a particular vehiclecomponent 40.

An electronic circuit 14 may then be applied in step 54 of method 50 byprinting a conductive ink on the first side 6 of the leather substrate4. The conductive ink can be applied through any suitable process ortechnique, and in an illustrative embodiment, is applied by one or moreof (a) screen printing, (b) aerosol jet printing, and (c) inkjetprinting. One or more electronic elements (e.g. a light source 18 suchas a micro LED) may optionally be arranged on the leather substrate 4 aspart of the circuit 14 in step 56 of method 50.

Then, the pigmented coating 26 can be applied on the circuit 14 in step58 of method 50. The pigmented coating 26 can include one or moreseparately applied layers with each including pigment, such that thepigmented coating 26 may inhibit or prevent the circuit 14 from beingvisible therethrough. The anti-soiling layer 28 is optionally applied onthe pigmented coating 26 in step 60 of method 50 to thereby produce afunctional leather assembly 2. Step 60 optionally includes applying anacrylic urethane resin anti-soiling component as part of the pigmentedcoating 26, and/or as a topcoat (i.e. an anti-soiling layer 28) that isseparate from and applied over the pigmented coating 26.

The functional leather assembly 2 is then embossed in step 48 of method44. Embossment may be accomplished by roll-to-roll embossing, forexample, by sending the functional leather assembly 2 through twoembossing rollers 30, 30 as indicated by the left-pointing arrow in FIG.2 , which thereby results in an embossed functional leather assembly 2.Embossment is performed such that the circuit 14 and associatedelectronic elements of the circuit 14 do not lose functionality. Theembossed functional leather assembly 2 can be arranged on a vehiclecomponent 40 so as to form a functional surface coving for the vehiclecomponent 40, which can then be used as a functional interior panel,seat, or steering wheel, for example. The method may also includeconnecting a microcontroller 38 to the circuit 14, for optionalconnection to a power source 36, ECU 32, and/or HMI 34, to allow thecircuit 14 to perform an operation.

It will be appreciated that various of the above-disclosed and otherfeatures and functions, or alternatives or varieties thereof, may bedesirably combined into many other different systems or applications.Also that various presently unforeseen or unanticipated alternatives,modifications, variations or improvements therein may be subsequentlymade by those skilled in the art which are also intended to beencompassed by the following claims

The invention claimed is:
 1. A functional leather assembly defining afirst surface and a second surface opposite from the first surface, thefunctional leather assembly including: a leather substrate comprising afirst side facing the first surface of the functional leather assembly,and a second side opposite from the first side and facing the secondsurface of the functional leather assembly; and an electricallyconductive trace arranged on the first side of the leather substrate; anembossed texture embossed directly into the first side of the leathersubstrate.
 2. The functional leather assembly according to claim 1,further including a wireless transmitter on the first side of theleather substrate and electrically connected to the electricallyconductive trace.
 3. The functional leather assembly according to claim1, wherein the electrically conductive trace includes a printed andcured electrically conductive ink.
 4. The functional leather assemblyaccording to claim 1, further including a light source on the first sideof the leather substrate and electrically connected to the electricallyconductive trace, the light source configured to emit light to provideillumination.
 5. The functional leather assembly according to claim 1,further including a pressure sensor on the first side of the leathersubstrate and electrically connected to the electrically conductivetrace.
 6. The functional leather assembly according to claim 1, whereinthe embossed texture includes one or more of: a roll-to-roll embossedtexture; a roll-to-plate embossed texture; a roll-to-die embossedtexture; a stamped embossed texture; a clamped embossed texture; apunched embossed texture; and a pressed embossed texture.
 7. Thefunctional leather assembly according to claim 1, further comprising amicrocontroller on the leather substrate and electrically connected tothe electrically conductive trace, the microcontroller being configuredto connect to an electronic control unit, a human machine interface, apower source, or combinations thereof.
 8. The functional leatherassembly according to claim 1, further comprising a pigmented coating onthe first side of the leather substrate and covering the trace.
 9. Afunctional leather assembly defining a first surface and a secondsurface opposite from the first surface, the functional leather assemblyincluding: a leather substrate comprising a first side facing the firstsurface of the functional leather assembly, and a second side oppositefrom the first side and facing the second surface of the functionalleather assembly; and a first electrically conductive trace arranged onthe first side of the leather substrate; a first electronic componentarranged on the first side of the leather substrate, electricallyconnected to the first electrically conductive trace, and having a firstfunctionality; a second electrically conductive trace arranged on thefirst side of the leather substrate and electrically isolated from thefirst conductive trace; a second electronic component arranged on thefirst side of the leather substrate, electrically connected to thesecond electrically conductive trace, and having a second functionalitydifferent than the first functionality; and an embossed texture embossedinto the first surface of the functional leather assembly.
 10. Thefunctional leather assembly according to claim 9, wherein the secondelectrically conductive trace overlaps the first electrically conductivetrace.
 11. The functional leather assembly according to claim 10,further including a dielectric layer arranged between the firstelectrically conductive trace and the second electrically conductivetrace, wherein the dielectric layer electrically isolates the secondelectrically conductive trace from the first electrically conductivetrace.
 12. The functional leather assembly according to claim 11,wherein the first electronic component includes a light source and thesecond electronic component includes a wireless transmitter.
 13. Thefunctional leather assembly according to claim 12, further including apressure sensor electrically connected to either the first electricallyconductive trace or the second electrically conductive trace.
 14. Thefunctional leather assembly according to claim 11, wherein the lightsource emits light for indicating a location of the wirelesstransmitter.
 15. The functional leather assembly according to claim 14,wherein the light source emits the light when a portable electronicdevice is within a predetermined distance from the functional leatherassembly.
 16. The functional leather assembly according to claim 9,wherein the first electrically conductive trace and the secondelectrically conductive trace include a printed and cured electricallyconductive ink.
 17. The functional leather assembly according to claim9, wherein the embossed texture includes one or more of: a roll-to-rollembossed texture; a roll-to-plate embossed texture; a roll-to-dieembossed texture; a stamped embossed texture; a clamped embossedtexture; a punched embossed texture; and a pressed embossed texture. 18.The functional leather assembly according to claim 9, further comprisinga microcontroller on the leather substrate and electrically connected tothe first electrically conductive trace and to the second electricallyconductive trace, the microcontroller being configured to connect to anelectronic control unit, a human machine interface, a power source, orcombinations thereof.
 19. The functional leather assembly according toclaim 9, further comprising a pigmented coating on the first side of theleather substrate and covering the first electrically conductive trace,the second electrically conductive trace, the first electroniccomponent, and the second electronic component.
 20. The functionalleather assembly according to claim 9, further including an anti-soilingcomponent layer arranged on the first side of the leather substrate andover the first electrically conductive trace and the second electricallyconductive trace.